Dana 35Donor Vehicles:CHEROKEE REAR 84-97, COMANCHE REAR 86-92, WRANGLER REAR 84-97, WAGONEER REAR 84-97Application: RearType: Semi-floatingAxle shaft diameter: 1.16 InchSpline count: 27Ring gear diameter: 7.56 InchMaximum tire size for stock axles: 33-inchMore Info
Dana 35 TTBApplications: FrontAxle Shaft Diameter: 1.16 InchesSpline count: 27Ring Gear Diameter: 7.56 InchMaximum tire size for stock axle: 33-inchStrong Points: Same knuckles and u-joints as Dana 44. 7.5" R&P are very strong. Have heard of virtually no failures. Can easily be lifted. Can easily be made to produce very good articulation with only the addition of longer radius arms and custom coils. Good aftermarket support, with many companies making lifts of all different sizes. Actually has hubs. Entire assembly is very strongWeak points: Wheel bearings- though large, are placed too close together. Automatic hubs- prone to grenading, or giving up when you need them most. Also, only very coarse adjustment available for wheel bearings. Radius arm bushings- especially passenger side frequently need replacing due to being too close to the catalytic converters. Brakes have a tendency to warp and/or crack the front rotors. Steering the stock steering set-up is very poor for a lifted truck. Severe bump steer is usually the result, in the higher lifts (4" and up)More Info

Dana 44 and TTBDonor Vehicles:K10,25,30,35,F 60-80, C10 REAR 60-70, W100-350 F 69-96, F100,150 4X4 R 67-78, F150,F250 F 75-90, F100,F150 F 78-90, IHC SCOUT 74-80, 86 CJ7 RearApplications: Front and rearType: Mainly semi-floating, although there were some very rare full-floating unitsAxle Shaft Diameter: 1.30 InchesSpline count: 30 (after '72; prior to '72, some were 19-spline)Ring Gear Diameter: 8.5 InchFactory ratios: 2.76:1 through 5.89:1Maximum tire size for stock axle: 35-inchWeight (solid axle): 240 PoundsStrong point: Wide availability and significant aftermarket support in parts and upgradesWeak point: Carrier and spider gears, U-joints, ring-and-pinionJunkyard jewel: Find a front axle out of an early '80s Dodge 3/4-ton because they were equipped with locking hubs. Also, a front axle out of a '76-or-earlier ½- or ¾-ton Chevy has steering knuckles that are cast flat and easily adaptable to crossover steeringBuilding secrets: Upgrade the stock carrier and spider gears because they're notoriously weak. Also, if you've indexed the axle to improve pinion angle, use a diff cover from a '78 or '79 Ford ¾-ton high-pinion '44 because it allows for a larger quantity of lube and a higher fill pointAftermarket alternatives: Currie Enterprises, Custom Differentials, DTS Custom Service, DynatracNotes: They came in both low-pinion and high-pinion models, and the centersection was even used in '80-and-up Ford Twin-Traction-Beam applications. They were offered in 5-, 6-, or 8-lug bolt patterns.More Info

Dana 60Donor Vehicles:K30,35 F 77-91, W200 250 F&R 69-93, W300 350 F 75-93, F100 R 67-85, F250 F&R 67-88Applications: Front and rearType: Semi- and full-floatingSpline count: 16, 23, 30, 32 and 35Factory ratios: 3.54:1 through 7.17:1Maximum tire size for stock axle: 38.5-inchWeight: 505 PoundsStrong point: Available in a variety of widths, most of which were full-floatersWeak point: The driver-side carrier bearing was known to spin on the carrier and this often spun the race, which can damage the housingJunkyard jewel: A heavy-duty front '60 can be found on '78 and '79 ¾-ton Ford pickups equipped with the snowplow package. Some late '70s and early '80s Dodge trucks had 35-spline '60 rear axles. Rear '60s are easy to find
Building secrets: The spider-gear roll pin is small and hollow, and is prone to breakage. Builders often double up the roll pin for extra strength (slide one inside of another). Also, replace the pinion yoke with a 1350-series yoke for extra strength. Finally, be careful about the spline count. Look for the 32- and 35-spline axles, avoid the 16s and 23sAftermarket alternatives: Currie Enterprises, DTS Custom Service, Dynatrac, Custom DifferentialsNotes: The venerable '60 has been available in either high- or low-pinion designs and was never used in an IFS application. Custom Differentials warns to steer clear of the rare but virtually identical Dana 61 because most of the parts are not interchangeableMore InfoDana 70Donor Vehicles:...Applications: Front and rearType: Most full-floating with some rare semi-floating in commercial applicationsSpline count: 23, 32 or 35Factory ratios: 3.54:1 through 7.17:1Maximum tire size for stock axle: 44-inchStrong point: Large teeth on ring-and-pinionWeak point: Small diameter pinion shaft (same as found on Dana 60)Junkyard jewel: Rarely seen but known to exist are open-knuckle front axles with disc brakes. A rear heavy-duty '70 was fitted under '73-'91 Chevy dualie pickups, and it has larger-than-normal carrier bearingsBuilding secrets: When rebuilding, make sure that any stock oil-restricting device is left in the pinion area. This keeps lube in the pinion-bearing area at a higher level and retains it longer. Custom Differentials says that a number of '70s come to them with the oil-restricting devices removedAftermarket alternatives: Dynatrac, Custom DifferentialsNotes: One of the benefits to a '70 is that there are a number of different pinion yoke sizes available, including a 1410-series yoke. Be careful though, because different housing castings used different sizes of pinion bearings due to different sizes of pinion boresMore Info

As a side note to this tech, do not confuse a Dana 61 for a 60. Easy to do as they are identical from all outward appearences. The difference is the pinion offset in the 61 is off by .25 - .375 or so.

These axles came with either 3.07 or 3.54 ratios and making one work is more expense than it is worth. Some folks have done it with spacers and used the open carriers with welding them up or using a lunchbox for the regular 60.

The 61 was available for either front or rear applications. Pirate4x4 does have a few articles about it and what people have done to overcome their dilema of pruchasing one of these bastard axles.

As a side note to this tech, do not confuse a Dana 61 for a 60. Easy to do as they are identical from all outward appearences. The difference is the pinion offset in the 61 is off by .25 - .375 or so.

That's not completely true. The Dana 61 can use either a Dana 60 or a Dana 61 gear set. This is not to say that they are interchangeable, but rather some Dana 61's used a Dana 60 gear set, which could not be replaced with a Dana 61 gear set, and vice versa.

That's not completely true. The Dana 61 can use either a Dana 60 or a Dana 61 gear set. This is not to say that they are interchangeable, but rather some Dana 61's used a Dana 60 gear set, which could not be replaced with a Dana 61 gear set, and vice versa.

This is true up to a 4.56 according to Eaton, after that the carrier will not accept the 60 gear set.